Board and method of manufacturing a board
AssigneeUnilin BV
InventorBenjamin Clement
Life of this patent
Estimating the term…
Abstract
A board includes at least a substrate which is formed at least of a gypsum-based and/or cement-based basic material layer with a compressive strength of 30 kg/cm2 and a resin-based covering provided on at least one side of the substrate, in the form of a laminate layer directly pressed onto the substrate.
Claims13
A board, comprising a substrate formed at least of a gypsum fiber board with a compressive strength of at least 30 kg/cm2 or a fiber cement board with a compressive strength of at least 30 kg/cm2, and a resin-based covering provided on at least one side of the substrate, in the form of a laminate layer directly pressed onto the substrate;
- wherein the resin-based covering comprises a first material sheet and a second material sheet;
- wherein the first material sheet comprises a first paper sheet impregnated with resin;
- wherein the second material sheet comprises a second paper sheet impregnated with resin;
- wherein the resin of the first material sheet is a thermohardening resin;
- wherein the resin of the second material sheet is a thermohardening resin;
- wherein the first paper sheet comprises a printed decor;
- wherein the second material sheet is provided onto the first material sheet;
- wherein the first material sheet is bonded onto the substrate by a resin bond provided by the thermohardening resin of the first material sheet;
- wherein the first material sheet is bonded to the second material sheet by the thermohardening resin of the first material sheet and the thermohardening resin of the second material sheet;
- wherein the board is a floor panel, a wall panel or a ceiling panel;
- wherein the board has a decorative appearance;
- wherein the substrate comprises reinforcement fibers, said reinforcement fibers consisting of wood fibers, wherein the reinforcement fibers are provided substantially over an entire thickness of the substrate;
- wherein said reinforcement fibers are blended in material of the gypsum fiber board or the fiber cement board;
- wherein the thermohardening resin of the first material sheet adheres to the reinforcement fibers of the substrate to form a connection;
- wherein the board, on at least two opposite edges, comprises coupling parts arranged for coupling two of such boards to each other, wherein the coupling parts are configured, in a coupled condition, to provide for a locking in a direction in a plane of the coupled boards and perpendicular to the coupled edges, and in a direction perpendicular to the plane of the coupled boards;
- wherein the coupling parts are made substantially or entirely in one piece in the substrate;
- and wherein the wood fibers extend into the coupling parts;
- wherein the coupling parts are provided with a material layer or material strip, which provides for a sealing of the coupling parts against absorption of moisture;
- wherein the resin bond is continuously present from on the resin-based covering up into the gypsum fiber board or the fiber cement board;
- wherein the resin of said resin bond extends at least up to a depth in said gypsum fiber board or the fiber cement board which is at least 0.5 millimeters.
Dependencies are inferred from the claim text.